DE4413951C1 - Seasoning sauce made from a koji starting material - Google Patents

Abstract

The present invention relates to a process for the production of a seasoning sauce using one or more microorganisms usual for the production of soy sauces, a fungus-covered, enzyme-containing koji substrate of divided bread having a high wheat gluten content being initially mashed with an enzymatic, salt-containing wheat gluten hydrolyzate, whereupon the fermentation is carried out in several steps, starting at 30 to 35 DEG C, via 40 to 45 DEG C in a later step to room temperature in the last step, without further enzyme addition for a total of 1 to 8 weeks. The resulting seasoning sauce has a soy sauce-like taste but a lighter color and high nitrogen and glutamate contents. The fermentation period can be reduced by a special process control.

Description

The invention relates to a method for producing a the well-known soy sauce similar to seasoning.

It is known to make soy sauce by a fermentation process produce, using soybeans, as whole beans or as defatted soybean meal and possibly wheat, mostly as roasted meal and salt in different proportions uses and starts from a kind of malt enzyme-containing, fungal substrate, called koji, produces, which is then mashed with salt water and a multi-stage fermentation, in which a combined hydrolytic process with lactic acid and alcoholic fermentation expires, and a ripening phase is subjected. As fermentation organisms, the Hyphal fungi of the genus Aspergillus oryzae or Asp. Soyae for the production of koji and the salt-tolerant lactococci Pediococcus halophilos and the yeast Zygosaccharomyces rouxii used in the fermentation phase. Modern processes in the Contrary to the past, where the natural accompanying flora  Fermentation caused defined starters. Of course fermented sauces do not use mineral acids to accelerate of the plant raw materials used, but this happens exclusively by means of enzymatic hydrolysis through the enzymes formed during the koji phase. Newer Developments use immobilized enzymes or immobilized microorganisms for fermentation. At then shorter fermentation time and reduced salinity when mashing is compared to the previous one Process the taste quality of the sauces worse. After a longer ripening phase (3-6 months) the mash by pressing, heating, sediment sediment and Layer filtering for a stable ready-to-eat sauce refined. The traditionally produced soy sauce has one dark color and a salty-full, roasted-malty aroma that is somewhat alien to western tastes. She points also due to the commonly used Raw materials only have a low content of free glutamate, which has a flavor-enhancing effect.

It is also known by means of plants, bacteria or Protease preparations obtained from mushrooms Vegetable proteins or to hydrolyze of animal origin. This hydrolysis are short-term processes without a maturity phase. Therefore have such processed and heated hydrolyzates also with higher digested nitrogen content and good Degree of hydrolysis little taste. They usually taste raw and not very harmonious. Methods are described, these Disadvantages due to the addition of microbial enzyme sources (US 4,587,127, US 4,684,527, DE 23 14 984) or glutaminase (DE 41 16 744, US 3852479) to eliminate. But there will be ultimately not significantly improved by this Get results.

The object of the present invention was a to produce soy sauce-like seasoning sauce, which, however, Has a lighter color than the familiar soy sauce, has a high glutamate content, less taste  roasted and neutral, but harmonious and so more of adapted to western tastes, and some has the lowest possible salt content. Another job consisted of getting more digested nitrogen in the product than is usually possible, but that Shorten manufacturing process and with a Process time of a few weeks to get by, despite short ripening time no more raw fruit character in the seasoning sauce should be ascertainable.

This should also be done without further enzyme additions (except Protease) and starter cultures (except Koji starter) achieved become.

JP-A-52-76488 describes a manufacturing process a seasoning sauce based on protein-containing raw materials, such as e.g. B. soybeans, soy protein, wheat, barley, wheat gluten, Corn glue, fish protein, milk protein etc. and carbohydrate-containing raw materials, such as. B. sorghum, rice bran, Wheat bran, potato, molasses, starch residues etc., from a koji using suitable koji organisms, such as especially Aspergillus soyae and Aspergillus oryzae is produced, which in a saline solution Temperatures between 30 and 55 ° C is fermented.

US-P-4 115 591 describes a method of manufacture a koji, with a koji mushroom in a modified one Koji substrate at a temperature of 20-40 ° C during 30-100 hours in the presence of 0.05 to 8% of a salt an aliphatic carboxylic acid with up to 4 carbon atoms is cultivated. The koji substrate will selected from the group consisting of soybeans, defatted soybeans, gluten, rice, wheat, wheat bran, Barley, oats, corn, fish meal and others. The so won Koji is fermented to produce Food products such as B. Soy sauce, miso and sake used, for example by fermentation in a 22% saline solution at 30 ° C for 150 days.  

EP-A-417 481 describes a process for the production a soy sauce by fermentation from a koji, by fermentation of a mixture of soybean meal and Wheat has been produced using a koji culture, after which the koji in aqueous suspension for 3-8 hours at 45-60 ° C with the enzymes that are used during fermentation the Kojikultur were obtained, is hydrolyzed, whereupon the Mix after adding sodium chloride to achieve a Salinity of 15-19% by weight of a 4-8 week fermentation is subjected.

U.S. Patent Nos. 3,912,822 and 3,852,479 describe using a method for producing a protein hydrolyzate high glutamic acid content by adding a glutaminase or microbial glutaminase source along with one proteolytic enzyme to a proteinaceous output material such as soybeans or wheat gluten is achieved. The salinity in the mash is 10-15 % By weight.

US Pat. No. 5,141,757 and EP 429 760 describe a method for Preparation of a seasoning in which an aqueous Suspension of a protein-rich material, e.g. B. degreased Soybean meal, hydrolysed by protease, this then subjected to heat treatment and then ripens by means of Koji additive. For this, the salinity set to 10-17% and inoculated with yeast. The process lasts up to 8 weeks before the mash goes through as usual Filtration and heating is worked up.

In Agric. Biol. Chem. 49, 745-750 (1985) growth and Respiratory coefficient of the Aspergillus oryzae fungus described, the fungus on a solid substrate is cultivated. Bread is used as a solid substrate. The koji thus obtained is not further fermented.  

DE-A1-42 35 928 describes a process for the production a seasoning sauce, initially using an enzyme-containing fungal substrate with saline water is mashed, the mash for a long time Subjected to fermentation and finally by pressing, Pasteurization and filtration is worked up, taking one bread divided into substrates with a high proportion of wheat gluten uses mashing with salt water so that in the mash the salt content is 4-12% by weight, preferably 7-8% by weight and the fermentation in several stages from 40-45 ° C in the first stage to room temperature in the temperatures falling during the last stage Performs 8-12 weeks.

It has now surprisingly been found that the Tasks according to the invention can be solved by a Modification of the latter method, whereby the Mash the bread koji not with salt water, but with an enzymatic, salty wheat gluten hydrolyzate is carried out, for example with such as he used in the process of EP 429 760 mentioned above becomes.

Through a certain procedure and the use of Raw materials traditionally not used for soy sauce production can be used, namely by using a enzyme-containing fungus-covered substrate (Koji) baked or extruded minced bread with high Wheat glue portion, which according to the invention with a enzymatic hydrolyzate of wheat glue (eHVP) instead is salted into a saline solution, special, achieved unexpected benefits. The hydrolysis conditions are chosen so that a rapid liquefaction takes place, the Hydrolyzate suspension is microbially so low that can be worked without further reheating and that Hydrolyzate doesn't taste bitter and a very low one Free amino acid content, but also pyroglutamic acid having.  

The invention thus relates to a method for Making a seasoning sauce using an or several more common for making soy sauces Microorganisms, where (A) is a fungus-covered, Enzyme-containing Koji substrate made from cut bread with high Wheat glue portion with (B) a saline aqueous Medium is mashed, (C) the mash in several stages subjected to fermentation for a long time and finally (D) by squeezing, pasteurizing and filtration is worked up, characterized in that one

• A) for the production of the koji substrate, a divided, through a traditional baking process from dough or by cooking extrusion of the protein-rich Uses raw material mix made bread,
• B) as a mashing liquid, an enzymatic, salty wheat gluten hydrolyzate with high Wheat glue in the form of a not reheated and unfiltered suspension used
• B1) where the ratio of koji substrate (A) to Wheat glue hydrolyzate (B) 50-200% by weight (based on Dry matter of the wheat glue hydrolyzate suspension) and the salt content of the mash is 3-10% by weight, preferably 5-8% by weight
• C) the fermentation in several stages initially 30-35 ° C over 40-45 ° C in a later stage up Room temperature in the last stage for a total Carried out for 1-8 weeks without further enzyme addition and finally
• D) the fermentation product in a manner known per se worked up.

The mashing with the koji takes place in one Ratio that the fermentation within 4 weeks can be ended. The processing takes place through Squeeze, pasteurize and then filter the Mash. This can be done in the usual way after concentration and drying a seasoning powder.

The production of the enzyme-containing, mushroom-covered Substrates, known in the technical language as koji, are made on traditional way, but using baked and cut bread with a high wheat gluten content. Alternatively the bread can also be made by extrusion. It is expedient to use a starter culture, preferably Aspergillus oryzae. A dense layer forms on the substrate Mushroom mycelium and this is made with an enzyme Proteolysis in wheat water obtained from saline water Mashed hydrolyzate.

It is preferred to produce the Wheat gluten hydrolyzate (eHVP) with a neutral protease Endopeptidase effect. The substrate is predominant from wheat glue, which in aqueous suspension with 5-30% by weight, preferably with 10-20% by weight, and for 1-6 hours at 40-65 ° C, preferably at 45-55 ° C Degrades substrate. The activity of the enzyme used leads to a clear liquefaction, but none worth mentioning Release of amino acids. Inexpensive from microbiological The point of view is hydrolysis at a salinity of 4-8% by weight NaCl.

The eHVP is then fresh, i.e. without reheating, at 30-35 ° C mixed with the Koji substrate to make it not to damage thermolabile enzyme activities. Within the kojienzymes set a significant amount within a few days Amino nitrogen and amino acids free and complete the Glue removal. To accelerate the fermentation, the Temperature then increased to 40-45 ° C for 1-2 weeks before one Short-term ripening takes place at room temperature. This can  a salt tolerant yeast such as Zygosaccharomyces rouxii Mash to be added. However, this is not mandatory necessary.

The starting material is preferably one of 20-80% by weight, preferably 30-60% by weight wheat gluten (protein content 80%) and 80-20% by weight of wheat flour and / or other additives (20-50% by weight) such as B. oatmeal, leguminous flour, Barley barley, milk and whey protein, yeast extract, Potato flakes, tomato powder using Baking agent made bread used, which in Form of slices, cubes, flakes or pellets of the koji Production and fermentation is subjected. The The bread is produced by a known method Bake the pastry or by extrusion of the moistened raw material mixture. For preservation and Storage of the baked bread can be frozen in one piece or air-dried in the usual way after grinding become. The extruded product can be stored directly. To defrosting or rewetting (to usual Fresh bread moisture) is both baked and that use extruded bread like fresh bread. The Bread texture (moisture, porosity) provides a good substrate Solid fermentation and the starter Aspergillus oryzae forms a dense layer on this adhesive-rich substrate white mycelium. During the koji phase, be on this Substrate especially the protein-degrading enzymes Exopeptidase activity including glutaminases educated.

While according to that described in U.S. Patent 3,912,822 Procedure a high glutamate content can only be achieved by adding glutaminase enzyme, according to the invention even higher glutamate content achieved without enzyme addition.

The targeted use of bread for koji fermentation brings surprisingly high hydrolytic activities, especially high glutaminase activity. This is expressed  in a high glutamate / nitrogen ratio. So a value of 1.2-1.4 is reached within 10 days, with a significantly higher nitrogen value (more than 2.5%) than in a common soy sauce.

Patent EP 0 429 760 describes reheating the eHVP as necessary. In the method according to the invention this is rather harmful, since this is from the intermediate released glutamine undesirable amounts Pyroglutamic acid can be formed. It has none flavor enhancing effect.

The low release of pyroglutamic acid (PG) by the The procedure described is documented by a PG / glutamate ratio less than 0.1 in the first 10 days of fermentation.

The mash is worked up in the usual manner Press filtration, heating and then clarification Membrane filtration (ultra or microfiltration on inorganic membranes). The clear seasoning liquid can be used Pre-concentrated drying, then with salt and others Carriers mixed, and then vacuum dried or spray dried.

example 1

In 10 l of water with 6% by weight NaCl, 1.5 kg of vital Wheat gluten (protein content 80%) stirred in. Of the Reference solution was previously 1% (based on substrate TS) Endoprotease added. Alternatively can also z. B. with 0.2% fungal protease Origin to be worked.

The contents of the container are kept stirring at 50 ° C held and incubated for a total of 3 hours, one significant liquefaction of the adhesive suspension is obtained. The hydrolyzate (eHVP) is freshly put, i.e. without filtration  and reheating at 30-35 ° C about 2 kg Koji substrate. The koji is made from bread with high Wheat glue portion. 750 g of vital wheat gluten are used (Protein content 80%) with 375 g wheat flour type 550 and 375 g of pea flour and 75 g of leavening agent are mixed and mixed in Add 1000 g of water to a firm dough. This is formed into a bread and bright at 220 ° C baked. The bread is cut into cubes and inoculated this with 1% of a spore suspension of Aspergillus oryzae (DSM 1863, culture sourced from the Deutsche Stammsammlung für Microorganisms).

You ferment the cubes on trays in one Temperature-controlled cabinet at 30 ° C and high humidity for about 50 hours (with intensive ventilation of the Substrate must be guaranteed) until there is a dense Mycelium has formed around the cubes (= Koji).

The entire koji is mashed into the eHVP without further salt addition. After 1-2 days, the koji becomes intense with mixed with the eHVP and initially for another 2-4 days at 30 ° C incubated before the fermentation temperature at occasional mixing at 40-45 ° C for 1-2 weeks is increased.

During the ripening phase at room temperature, the salt content in the Mash raised to 7% by weight by adding NaCl. To The mixture is ripened for 1-2 weeks by press filtration, Pasteurization and membrane filtration worked up. The The seasoning liquid obtained tastes full and harmonious.

Claims (5)

1. A process for the production of a seasoning sauce using one or more microorganisms customary for the production of soy sauces, wherein (A) a mushroom-covered, enzyme-containing koji substrate made from split bread with a high wheat gluten content is mashed with (B) an aqueous medium containing saline, ( C) the mash is subjected to fermentation for a long time in several stages and finally (D) is worked up by pressing, pasteurization and filtration, characterized in that

• A) for the production of the koji substrate, a piece of bread is used which is made from dough by a traditional baking process or by a cooking extrusion of the protein-rich raw material mixture,
• B) an enzymatic, salt-containing wheat gluten hydrolyzate with a high proportion of wheat glue is used as the mashing liquid in the form of an unheated and unfiltered suspension,
• B1) the ratio of koji substrate (A) to wheat glue hydrolyzate (B) 50-200% by weight (based on the dry matter of the wheat glue hydrolyzate suspension) and the salt content of the mash 3-10% by weight, preferably 5-8% by weight. %,
• C) the fermentation in several stages at an initial 30-35 ° C over 40-45 ° C in a later stage to room temperature in the last stage for a total of 1-8 weeks without further enzyme addition and finally
• D) the fermentation product is worked up in a manner known per se.

2. The method according to claim 1, characterized in that as substrate A one of 20-80% by weight, preferably 30-60% by weight Wheat glue and 80-20% by weight wheat flour and / or others Additives such as oatmeal, potato flakes, Leguminous flour, barley barley, milk and whey protein and / or yeast extract or tomato powder using Bread made with water and raising agents which is in the form of slices, cubes, flakes or Pellets subjected to koji production and fermentation becomes. 3. The method according to claim 1 or 2, characterized in that a substrate is used as the wheat gluten hydrolyzate (B), obtained from a 5-30 wt% aqueous Wheat glue suspension, which is kept at 40-65 ° C for 1-6 hours using a neutral protease with endopeptidase activity has been hydrolyzed. 4. The method according to claim 3, characterized in that hydrolysis with a saline content of 4-8% by weight has been carried out. 5. The method according to any one of claims 1-4, characterized characterized in that the mashing of the koji substrate (A) with the wheat gluten hydrolyzate (B) at a temperature of 30-35 ° C takes place.